REXROTH MKE Series Technical manual

R911297663
Edition 03
Rexroth MKE synchronous motors
for potentially hazardous areas
acc. to ATEX and UL/CSA guidelines
Project Planning Manual
Industrial
Hydraulics
Electric Drives
and Controls
Linear Motion and
Assembly Technologies Pneumatics
Service
Automation
Mobile
Hydraulics

About this Documentation MKE
DOK-MOTOR*-MKE*GEN2***-PR03-EN-P
Rexroth MKE synchronous motors
for potentially hazardous areas
acc. to ATEX and UL/CSA guidelines
Project Planning Manual
DOK-MOTOR*-MKE*GEN2***-PR03-EN-P
Document Number: 120-1500-B326-03/EN
This documentation describes …
•Explains the features of the product, possibilities for use, conditions
for use and operational limits
•Contains technical data regarding the motors that can be supplied
•Provides information regarding product selection, handling and
operation
Description Release
Date Notes
DOK-MOTOR*-MKE*GEN2***-PR01-EN-P 06/03 1st edition (not printed)
DOK-MOTOR*-MKE*GEN2***-PR03-EN-P 02/04 2nd edition
DOK-MOTOR*-MKE*GEN2***-PR03-EN-P 03/04 3rd edition
2004 Bosch Rexroth AG
Copying this document, giving it to others and the use or communication
of the contents thereof without express authority, are forbidden.
Offenders are liable for the payment of damages. All rights are reserved
in the event of the grant of a patent or the registration of a utility model
or design (DIN 34-1).
The specified data is for product description purposes only and may not
be deemed to be guaranteed unless expressly confirmed in the contract.
All rights are reserved with respect to the content of this documentation
and the availability of the product.
Bosch Rexroth AG
Bgm.-Dr.-Nebel-Str. 2 •D-97816 Lohr a. Main
Telephone [phone] •Tx 68 94 21 •Fax [phone]
http://www.boschrexroth.com/
Dept. BRC/EDM2 (MH/JW)
This document has been printed on chlorine-free bleached paper.
Title
Type of Documentation
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Internal File Reference
Purpose of Documentation
Record of Revisions
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Note

MKE Contents I
DOK-MOTOR*-MKE*GEN2***-PR03-EN-P
Contents
1 Introduction to the Product 1-1
1.1 MKE.........................................................................................................................................1-1
1.2 About this documentation.........................................................................................................1-3
2 Important Instructions on Use 2-1
2.1 Intended Use............................................................................................................................2-1
Introduction .........................................................................................................................2-1
Fields of Use and Application ..............................................................................................2-2
2.2 Non-Intended Use....................................................................................................................2-2
3 Safety Instructions for Electric Drives and Controls 3-1
3.1 Introduction..............................................................................................................................3-1
3.2 Explanations ............................................................................................................................3-1
3.3 Hazards by Improper Use.........................................................................................................3-2
3.4 General Information..................................................................................................................3-3
3.5 Protection Against Contact with Electrical Parts........................................................................3-5
3.6 Protection Against Electric Shock by Protective Low Voltage (PELV)........................................3-6
3.7 Protection Against Dangerous Movements...............................................................................3-7
3.8 Protection Against Magnetic and Electromagnetic Fields During Operation and
Mounting..................................................................................................................................3-9
3.9 Protection Against Contact with Hot Parts...............................................................................3-10
3.10 Protection During Handling and Mounting...............................................................................3-11
3.11 Battery Safety.........................................................................................................................3-12
3.12 Protection Against Pressurized Systems.................................................................................3-13
4 Technical data 4-1
4.1 Description...............................................................................................................................4-1
Operating Modes.................................................................................................................4-2
Definition of Parameters......................................................................................................4-3
4.2 Technical Data MKE037...........................................................................................................4-6
Technical data sheet and characteristic curves....................................................................4-6
Shaft loads..........................................................................................................................4-8
4.3 Technical Data MKE047.........................................................................................................4-10
Technical data sheet and characteristic curves..................................................................4-10
Shaft loads........................................................................................................................4-12
4.4 Technical Data MKE098.........................................................................................................4-14
Data sheet and characteristic curves .................................................................................4-14
Shaft loads........................................................................................................................4-16
4.5 Technical Data MKE118.........................................................................................................4-18

II Contents MKE
DOK-MOTOR*-MKE*GEN2***-PR03-EN-P
Data sheet and characteristic curves .................................................................................4-18
Shaft loads........................................................................................................................4-22
5 Dimensional Details 5-1
5.1 Size 037...................................................................................................................................5-1
5.2 Size 047...................................................................................................................................5-4
5.3 Size 098...................................................................................................................................5-7
5.4 Size 118.................................................................................................................................5-10
6 Type Code 6-1
6.1 Description...............................................................................................................................6-1
6.2 Type code size 037..................................................................................................................6-6
6.3 Type code size 047..................................................................................................................6-7
6.4 Type code size 098..................................................................................................................6-8
6.5 Type code size 118..................................................................................................................6-9
7 Accessories and Options 7-1
7.1 Motor encoder..........................................................................................................................7-1
7.2 Holding Brakes.........................................................................................................................7-3
7.3 Gearboxes...............................................................................................................................7-4
Planetary gearbox...............................................................................................................7-4
8 Connection System 8-1
8.1 Overview..................................................................................................................................8-1
Connection temperature control...........................................................................................8-2
Additional protective conductor............................................................................................8-2
Connection Cable................................................................................................................8-3
8.2 Motor connection according to European standard (EN)...........................................................8-4
8.3 Connection according to American standard (UL).....................................................................8-5
8.4 Dimensioning power cable........................................................................................................8-6
8.5 Recommendation for handling and application, Cable assembly in drag chains ........................8-7
9 Notes Regarding Application 9-1
9.1 Hazardous areas......................................................................................................................9-1
Designation and definition ...................................................................................................9-1
Application conditions for MKE motors.................................................................................9-6
Type test of the motors according to European standard (EN) .............................................9-9
Type test of the motors according to American standard (UL)............................................9-11
9.2 Setup Height and Ambient Temperature.................................................................................9-13
9.3 Protection class......................................................................................................................9-14
9.4 Compatibility ..........................................................................................................................9-14
9.5 Design and Installation Positions............................................................................................9-15
9.6 Prime Coat and Housing Varnish............................................................................................9-15
9.7 Vibration and Shock Loads.....................................................................................................9-16
9.8 Output shaft and shaft sealing ring .........................................................................................9-17
Smooth shaft.....................................................................................................................9-17

MKE Contents III
DOK-MOTOR*-MKE*GEN2***-PR03-EN-P
Output shaft with fitting key................................................................................................9-17
Output Shaft With Shaft Sealing Ring................................................................................9-18
9.9 Bearings and Shaft Load........................................................................................................9-20
9.10 Holding Brakes.......................................................................................................................9-24
Selecting Holding Brakes...................................................................................................9-25
Sizing of Holding Brakes (Application) ...............................................................................9-26
9.11 Acceptance and allowance.....................................................................................................9-27
Motors in EU style .............................................................................................................9-27
Motors in UL style..............................................................................................................9-28
10 Handling, Transport and Storage 10-1
10.1 Supplied Condition.................................................................................................................10-1
Factory-attached test.........................................................................................................10-1
Test on the customer side .................................................................................................10-1
10.2 Identification...........................................................................................................................10-2
Shipping documents and delivery note...............................................................................10-2
Name plate........................................................................................................................10-2
10.3 Transport and storage............................................................................................................10-3
11 Installation 11-1
11.1 Safety ....................................................................................................................................11-1
11.2 Skilled technical personnel.....................................................................................................11-1
11.3 Mechanical mounting –Motor assembly.................................................................................11-2
Mounting the flange...........................................................................................................11-2
Preparation .......................................................................................................................11-2
Assembly ..........................................................................................................................11-3
11.4 Electrical connection –Motor connection................................................................................11-3
Motor connection according to European standard (EN)....................................................11-4
Motor connection according to American standard (UL)...................................................11-11
12 Startup, Operation and Maintenance 12-1
12.1 Commissioning.......................................................................................................................12-1
12.2 Operation...............................................................................................................................12-1
12.3 Deactivation...........................................................................................................................12-2
12.4 Maintenance ..........................................................................................................................12-2
Cleaning............................................................................................................................12-2
Bearing .............................................................................................................................12-3
Connection Cable..............................................................................................................12-3
Holding brake....................................................................................................................12-4
Changing the battery.........................................................................................................12-5
12.5 Troubleshooting .....................................................................................................................12-7
12.6 Dismantling............................................................................................................................12-7
12.7 Waste disposal.......................................................................................................................12-8
13 Appendix 13-1
13.1 List of standards.....................................................................................................................13-1

IV Contents MKE
DOK-MOTOR*-MKE*GEN2***-PR03-EN-P
13.2 Selection of connection cable.................................................................................................13-3
Power cables.....................................................................................................................13-4
Encoder cable ...................................................................................................................13-7
13.3 Declaration of conformity........................................................................................................13-9
14 Service & Support 14-1
14.1 Helpdesk................................................................................................................................14-1
14.2 Service-Hotline.......................................................................................................................14-1
14.3 Internet...................................................................................................................................14-1
14.4 Vor der Kontaktaufnahme... - Before contacting us.................................................................14-1
14.5 Kundenbetreuungsstellen - Sales & Service Facilities.............................................................14-2
15 Index 15-1

MKE Introduction to the Product 1-1
DOK-MOTOR*-MKE*GEN2***-PR03-EN-P
1 Introduction to the Product
1.1 MKE
The MKE-servo motors of the second generation fulfill the specifications
according to ATEX and UL/CSA in one class. This permitts the
worldwide use of Rexroth MKE-motors with one machine design only.
In connection with the drive devices of Rexroth, the MKE-servomotors
generates drive systems with high functionality for the use in hazardous
areas.
MKE-motors are available in the following power spectrum:
Fig. 1-1: MKE power graduation
MKE motors are characterized by the following advantages:
•The motor construction in “Flameproof Enclosures “d” ” according to
EN 50 014 : 1992
•High operational reliability
•Maintenance-free operation (owing to the brushless design and use
of bearings grease-lubricated for their entire service life)
•Use under adverse environmental conditions is possible (owing to the
completely closed motor design in IP 65 degree of protection
•Overload protection (by means of motor-temperature control)
•High performance data
•High dynamics (owing to the favorable ratio of torque to inertia mass)
•High overload capability (owing to the favorable heat dissipation from
the stator windings to the outside wall of the motor housing)
•Peak torque utilizable across a wide speed range (owing to electronic
commutation)
•Continuous start-stop operation possible with high repeat frequencies
(owing to electrical commutation)
•Easy attachment to the machine (owing to flange according to DIN
42948) 11.65)
•Any installation position desired
•Simple and fast commissioning (by data memory)
Performance list
Performance feature
Motor Drehzahl
MKE037B 9000
MKE047B 6000
MKE098B 3200
MKE118B 2000, 4000
MKE118D Lüfter 2000
Drehmoment Nm
35 40 45 5010 15 2052530

1-2 Introduction to the Product MKE
DOK-MOTOR*-MKE*GEN2***-PR03-EN-P
MKE motors are permanent-magnet motors with electronic commutation.
Special magnet materials permit the motors to be designed with low
inertia masses. The following figure shows the principal design of MKD
motors.
23
4
56
8
9
3
10
1
7
MG000011v01_NN.FH10
(1): Shaft
(2): Stator with winding
(3): Bearing
(4): Motor encoder
(5): Connection unit
(6): Terminal box lid
(7): Holding brake (optional)
(8): Grounding clamp
(9): Shaft sealing ring
(10): Rotor with permanent magnets
Fig. 1-2: Design of MKE motors
Constructions
MHE motors are available in various designs. Conditional upon existing
national instructions and standards, the MKE motors have to be
defferentiated from the housing according to:
•E according to European Standard (EU) and
•U according to American Standard (UL)
unterteilt werden.
The connection technology of the MKE motors is variously processed
according to the national instructions.
Note: Please heed the notes according to the guilty national
instructions in the chapter “Application Notes”.
Design and components

MKE Introduction to the Product 1-3
DOK-MOTOR*-MKE*GEN2***-PR03-EN-P
1.2 About this documentation
Structure of this Document Edition
The present documentation contains safety regulations, technical data,
and operating instructions for MKE motors. The individual chapters can
be subdivided into the following focal points:
Chapter Title Content
1 Introduction to the Product General information
2 Important Instructions on Use
3 Safety notes Safety
4 Technical data
5 Dimensional Details
6 Type Code
Product description
(for planners and machine
constructors)
7 Accessories and Options
8 Connection System
9 Operating condition and application
instructions
10 Handling, Transport and Storage
11 Installation
12 Startup, Operation and Maintenance
Practical
(for operating and
maintenance personnel)
13 Appendix
14 Service and Support
15 Index
General information
Fig. 1-3: Document Structure

1-4 Introduction to the Product MKE
DOK-MOTOR*-MKE*GEN2***-PR03-EN-P
Modifications as Compared with the Predecessor
Version
The following list shows the modifications as compared with the
predecessor version DOK-MOTOR*-MKE*GEN2***-PR02 -EN-P
Where? What?
Chapter 3.9 Safety note “Protection against contact with hot parts”appendix.
Chapter 4.4 New: Technical data and characteristic curve MKE098B-058
Chapter 4.5 New: Technical data and characteristic curve MKE118D-035
Chapter 6.4 New: Type code size 098
Chapter 9.1 Revision of section “Application conditions for motors MKE”.
Chapter 11.4 Fig. 1-4: Grommets for Ex-threads (adjustment of grommet size for
encoders)
Chapter 12.4 Maintenance –battery change
Fig. 1-5: Modifications
Note: This list does not lay claim to completeness. The author
reserves the right to neglect minor modifications in this list.